Control switch with toggle arrangement



Dec. 5, 1961 D. L. COSPER CONTROL SWITCH WITH TOGGLE ARRANGEMENT Filed March 25, 1960 2 Sheets-Sheet 1 lg. w

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Dec. '5, 1961 D. L. COSPER CONTROL swrrcu WITH TOGGLE ARRANGEMENT Filed March 25, 1960 2 Sheets-Sheet 2 l I w United States Patent 3,012,114 CONTROL SWITCH WITH TOGGLE ARRANGEMENT Dale L. Qosper, South Bend, Ind., assignor to Versal, Inc, South Bend, Ind., a corporation of Indiana Filed Mar. 25, 1960, Ser. No. 17,649 7 Claims. (Cl. 200-67) The invention relates to electric switch devices and has more particular reference to an electric switch for controlling the direct current supplied to an electric motor such as may be employed for propelling golf carts and similar vehicles.

Electric powered cars of the three or four wheel type, as typified by a golf cart, incorporate a pair of motor driven rear wheels and the control for the motor provides for several speeds between an open circuit position and a fully closed circuit position. Since high amperage direct current is involved, the switch structure for controlling fiow of the direct current to the driving motor has presented problems in design and in mode of operation. The use of automobile starting relays has not been satisfactory because the contacts may become welded due to the high currents involved. In addition to overcoming this objectionable feature, the switch structure employed must be relatively simple and economical to manufacture and yet the structure is required to operate successfully for long periods without the need for servicing. Also, the device must incorporate one or more speed settings between open and fully closed positions.

The main objective of the invention is to provide an electric switch of the controller type which will incorpcrate special design features particularly adapting the switch for use as a controller in the operation of direct current electric motors.

Another object of the invention is to provide a controller type switch having a slow speed contact, an intermediate contact and a high speed contact and which are successively engaged as the switch is actuated to and from open and high speed positions.

A more specific object resides in the provision of a three speed controller type switch which will incorporate a toggle arrangement in connection with the slow speed contacts whereby arcing is completely eliminated when the wiping arm of the switch moves from a circuit on to a circuit off position.

Another object of the invention is to provide switch structure capable'of handling high amperage direct current and which will include a toggle arrangement in connection with one of the contacts, the same having snap action to open and close the electric circuit through the contacts as the wiping arm is moved to and from an off and a fully closed circuit position.

With these and various other objects in view, the invention may consist of certain novel features of construction and operation, as will be more fully described and particularly pointed out in the specification, drawings and claims appended thereto.

In the drawings which illustrate an embodiment of a the device and wherein like reference characters are used to designate like parts FIGURE 1 is avplan view of the controller switch of the invention showing the wiping arm of the switch in a high speed position, and with the toggle ,contac in closed circuit position;

FIGURE 2 is an end view of the switch of FIGURE 1, taken substantially along line 22 and looking in the direction of the arrows;

FIGURE 3 is a plan View of the controller switch similar to FIGURE 1 but showing the wiping arm in an 3,012,114 Patented Dec. 5, 1961 ice off position and with the toggle contact in open circuit position;

FIGURE 4 is a side view of the switch taken at the left hand side and looking towards the right with the wiping arm in the high speed position of FIGURE 1.

Referring to the drawings the embodiment selected for illustrating the present invention essentially includes a base member 10 of insulating material, such as Bakelite, or other strong and durable plastic, to which the elements of the switch may be secured in an insulated manner. Said securing instrumentalities include a pair of metal posts such as 11 and 12 which extend through openings in the insulating base and are secured to the base by the securing nuts 13 and 14. The posts project a suitable distance from the base 10, and said projecting ends have fixedly mounted thereon the metal plate 15. Post 11 receives the securing nut 16 for fastening the right hand end of the plate 15 to the post, FIGURES 1, 2 and 3, whereas post 12 in a similar manner receives the securing nut 17, which connects the left hand end of the plate 15 to the post. The plate 15 is provided with a stop flange 18 located approximately intermediate the posts 11 and 12 and adjacent one side of the plate as clearly evident in FIGURES l and 3. The stop flange 18 has utility in connection with the toggle arrangement which will presently be described in detail.

Post 11 provides a convenient terminal for the electric circuit to be controlled by the switch, and accordingly the conductor 26 from the battery or other source of direct current, terminates in the cable connector 21 and which is suitably secured to the post 11 by the securing nut 16. Two flexible conductors have electrical connection with said post and the post accordingly functions as one ter minal of the present switch. Conductor'22 having the cable connector 23 is secured to the post at said cable connector end by the nut 16 and it will be observed that the other end of the conductor 22 is suitably secured as by welding at 24 to the oscillatable wiper arm 25. Welding is preferred at 24 since a good connection is desired between conductor 22 and the wiping arm 25 for which purpose the arm is preferably formed of copper. The flexible conductor 26 having the cable connector 27 is also secured at its cable connector end to the post 11 by the nut 16. The opposite end of conductor 26 is suitably welded at 28 to the toggle contact 30. Welding is also preferred at 28, since good conductivity is required and the toggle contact is formed of cop-per for the same purpose.

The insulating base 10' at one end thereof, as best shown in FIGURE 1, carries a pair of copper contacts and a slide plate all for coaction with the oscillatable wiper arm. The slide plate 31 is formed of metal although not necessarily copper, and the same is secured to the base 10 by means of the screws 32 or similar securing means. The intermediate or second speed contact is indicated by numeral 33, and said contact is fixed to the base 10 by securing screws such as 34. V The contact 32 is preferably formed of copper, asis also the high speed contact 35 which is'fixed to the base by the screws 36. The first or slow speed contact 37 is supported by the metal plate 15 being fixed to said plate atthe left hand end thereof,

FIGURES 1 and 3, by means of securing screws to which are threaded the socket nuts 38. It is necessary to insulate the contact 37 from the metal plate 15, and for this purpose thereis interposed between the contact and the plate an insulating member 40. Also, bushings 41 of insulating material surround the securing screws for the contact 37 and said bushings have a location between the plate 15 and the socket nuts 38. In this manner the first or slow speed contact 37 is fixedly held to the metal plate 15 and properly oriented although the contact is serves to connect the arm 53 to the wiping arm 25.

completely insulated from the plate and incapable of conducting any current to or from the plate. As best shown in FIGURE 3 the face 42 of contact 37 extends a short distance beyond the edge 43 of the metal plate 15, and thus the face 42 of the contact is conveniently positioned for coaction with the toggle contact 30 which will now be described in connection with the'oscil-latable Wiping arm 25.

The wiper arm 25 is mounted for osoillatable movement by the pivot pin 45 which is journalled by the base and the metal plate 15. The toggle contact 30 is also mounted for oscillatable movement by the pivot pin 45, and Whereas the wiping arm is located adjacent the base 10, it will be observed that the toggle contact is located adjacent the metal plate 15. Both the wiping arm and the toggle contact are journailed by the pivot pin so as to have movement independently of each other and yet both of these oscillatable members are held against axial'displacement longitudinally of the pivot pin. Split washers received by grooves on the pin may be employed for retaining the wiping arm and the toggle contact in desired position on the pivot pin, and such structure will not interfere with the free oscillatable movement of each member.

The pivot pin 45 extends through the base and also the metal plate. However, the portion of the'pin extending through the base projects some distance beyond the same to receive the cap washer 46. The coil spring 47 has encircling relation with the projecting portion of the pin, andthe coil spring is confined between the cap washer 46 and the base 10. Accordingly, the pin is urged in a direction to hold the Wiping arm 25 close to the base 10, and accordingly the arm has good wiping action with the contacts 33 and 35, and also with the slide plate 31. The resilient tension exerted by coil spring 47 on the pivot pin 45 is additionally converted into a friction brake for the wiping arm 25. The brake is best illustrated in FIGURE 4 wherein the actuating stud 43, and which is suitably secured to the actuating end of the Wiping arm, is provided with a friction pad 50. The enlarged base or" the stud retains the same as the wiping arm, and the surface of the base carries the friction pad which contacts the rather smooth surface of the base 10. However, suflioient drag is imparted to the wiping arm to prevent inadvertent movement of the same, such as might otherwise result due to vibration to which the switch structure is normally subjected.

Whereas the wiping arm is adapted to contact the slide plate 31 and the contacts 33 and 35, the toggle contact 30 has contact only with the face-'12 of the contact 37 and the stop 18. The toggle action of the contact 30 is produced by the coil spring 52 having the terminal arms 53 and 54; Arm 53 is flanged at 55, and the said flange end In a similar manner, arm 54 is flangedat 56 and the said flange serves to connect the arm 54 to the toggle contact 30. The action of the coil spring 52 is such that it rotates with the flanged end 56 acting as a pivot, and with respect to certain dead center positions, the toggle contact 30 will be urged either in a circuit closing position or in a circuit open position. FIGURE 1 illustrates the circuit closed position of the toggle 30 wherein the same is resiliently biased by the spring 52 in a counterclockwise direction so that the contact has engagement with face 42 of contact 37. In the circuit open position as shown in FIGURE 3, the coil spring 52 biases the contact 30 toward the stop flange 18 provided by the metal plate 15. This shifting as regards the position of the coil spring '52 is effected by the wiping arm 25 which, as explained, has connection with the spring by reason of the flanged end 55. The dead center position is reached when the wiping arm is substantially parallel and aligned with the toggle contact in its positio'n of FIGURE 3. The end of the wiping arm still has contact with the slide plate 31, althoughmovement in one direction or the other will eifect snap action of the toggle contact 30 into contact with the face 42 or into contact with the stop 18. When the wiping arm is rotated clockwise it will be seen that the toggle contact is given a snap motion in the opposite direction or counterclockwise. Also when the wiping arm is rotated counterclockwise to open the electric circuit, the toggle contact is given snap motion in a clockwise direction to also open the circuit controlled by it.

The conductor 20 was previously described as having connection to the battery or to any other source of direct current. The high speed contact 35 is suitably connected by means of conductor 57 with the motor to be controlled. In a similar manner conductor 58 connects the slow speed contact 37 to contact 35 through the resistance 60. The intermediate contact 33 is adjustably connected at any desired point along the resistance 60 by means of the conductor 61. Accordingly, it will be seen that when the wiping arm 25 is rotated counterclockwise, FIGURE 3, to a position against post 12 which acts as a stop therefor, the toggle contact 36 will be resiliently urged into engagement with the stop flange 18. The circuit to the motor is therefore open, since the toggle contact is the only element of the switch having engagement with the slow speed contact 37. The slide plate 31 is not included in the electrical circuit, since the plate is secured to the insulating base 10 and is separate from the other elements.

When it is desired to start the motor, the wiping arm 25 is rotated in a clockwise direction and when the arm reaches a position approximately parallel and in alignment with the contact 30, a dead center position will have been reached and the contact 30 will thereafter snap into its operative position of FIGURE 1 so that the circuit to the motor is now closed through the contact 30, contact 37, conductor 58 and the resistance 60. Since all of the resistance is included in the motor circuit, the motor will operate at a slow speed.

It will be understood that snap action of the contact 30 from the position of FIGURE 3 to the operative position of FIGURE 1, takes place while the wiping arm 25 is still in engagement with the slide plate 31. If it is desired to speed up the motor, rotation of the wiping arm is continued ina clockwise direction until the arm is in engagement with contact 33. This second or intermediate position of the; arm will supply current to the motor through said arm, contact 33, conductor 61, and a portion of the resistance 60, depending on the location of the adjustable connection 62.

If rotation of the wiping arm is continued until the same engages the post 11, which functions as a stoptherefor, it will be seen that the arm will engage the high speed contact 35. Accordingly, the circuit to the motor is completed through the arm and the contact, with all of the resistance 60 being cut out of circuit. This constitutes the high speed position for the wiping arm, and said arm in this position and also in its intermediate position, will be frictionally held by reason of the tension exerted by the coil spring 47, and the friction drag developed-by the pad 50. a

The electric circuit to the motor is opened by rotating the wiping arm in a counterclockwise direction. The toggle contact 31) will remain in engagement with the contact 37 until the wiping arm has rotated counterclockwise into engagement with the slide plate 31. Further movement of the arm 25 along said plate will position the parts beyond dead center and the toggle contact 33 will snap back into contact with the flange 1 8. This snap :action of contact 30 by reason of the toggle arrangement substantially eliminates arcing between the same and contact 37. g

The invention is not to be limited to or by details of construction of the particular embodiment thereof illustrated by the drawings, as various other forms of the de-- vice will, of course, be apparent to those skilled in the art without departing from the spirit of the invention or the scope of the claims.

What is claimed is:

1. In a controller type switch of the character de scribed, the combination including a pair of spaced parallel members, a pivot pin journalled by the spaced members and disposed normal thereto, a first insulated contact fixed to one of said members, a wiping arm mounted by the pin for oscillating movement and adapted to engage the first insulated contact when in closed circuit position, a second insulated contact fixed to the other member, a toggle contact also mounted by the pivot pin for oscillating movement and adapted to engage the second insulated contact when in closed circuit position, and a toggle spring connecting the wiping arm and the toggle contact, said arm, spring and toggle contact being so constructed and arranged whereby movement of the wiping arm from engagement with the first insulated contact to an open circuit position effects snap action of the toggle contact from engagement with the second insulated contact into an open circuit position, said movement of the toggle contact taking place in a direction opposite to that of the wiping arm.

2. In a controller type switch of the character described, the combination including a base member of insulating material, a metal plate member secured to the base in spaced parallel relation, a slide plate, an intermediate contact and a high speed contact fixed to the base and insulated from each other, a pivot pin journalled by the base and plate members, a wiping arm mounted by the pivot pin for oscillating movement parallel to the base member, whereby said arm will selectively engage the slide plate, the intermediate contact and the high speed contact as it is caused to oscillate, an insulated contact fixed to the metal plate, a stop flange provided by the metal plate in spaced relation with the insulated contact, a toggle contact also mounted by the pivot pin and adapted to oscillate to and from engagement with the insulated contact and the stop flange, and a toggle spring connecting the wiping arm and the toggle contact, said toggle spring, arm and toggle contact being constructed and arranged whereby oscillating movement of the wiping arm to a predetermined extent in one direction will eflect a snap action movement of the toggle contact in an opposite direction.

3. A controller type switch as defined by claim 2, wherein the wiping arm is adapted to have wiping contact with the slide plate and with the intermediate and high speed contacts as the arm oscillates, and additionally including resilient means in associated relation with the pivot pin for yieldingly biasing the wiping arm toward the insulating base to thereby insure good wiping contact of the arm with the said elements.

4. A controller type switch as defined by claim 2, wherein said toggle spring, arm and toggle contact are in an approximate dead center position when the arm is positioned in parallel alignment with the toggle contact, and wherein said slide plate and intermediate contact are so located that the arm is in engagement with the slide plate and out of engagement with the intermediate contact when in said approximate dead center position.

5. In a controller type switch for high amperage direct current operation, in combination, a base member of insulating material, a plate member secured to the base in spaced, parallel relation, a first and a second stop member located in spaced relation and fixed to the base, a pivot pin mounted by the base and plate members and disposed approximately normal thereto, a wiping arm journalled by the pivot pin for oscillating movement parallel to the base and between the first and the second stop members, a plurality of contacts fixed to the base and with which the arm is adapted to have wiping action, one of said contacts being disposed adjacent the second stop member so that the wiping arm engages the same when against the second stop member, a toggle contact also journalled by the pivot pin, an insulated contact secured to the plate member adjacent the first stop member, a stop flange provided by the plate member and spaced from the insulated contact, said toggle contact having oscillating movement between the insulated contact and the stop flange, and a toggle spring connecting the wiping arm and the toggle contact, whereby oscillating movement of the toggle arm takes place with snap action as the wiping arm is moved beyond dead center positions.

6. A controller type switch as defined by claim 5, wherein the wiping arm is formed of metal, and additionally including resilient means associated with the pivot pin and functioning to insure a good wiping action of the arm with the contacts which are fixed to the base.

7. A controller type switch as defined by claim 5, wherein the toggle contact, spring and arm are so constructed and arranged that movement of the arm in one direction efi'ects snap acting movement of the toggle contact in a reverse direction.

References Cited in the file of this patent UNITED STATES PATENTS Re. 24,218 Mucher Sept. 18, 1956 

